RE-SMOG! Need Help!

[2mbb]

I'm still trying to figure out a couple ones that I don't see in the emissions manual, but will do some more searching on here to try and figure them out. I know one is for the A/C idle up and isn't covered in the manuals. The other is on the passenger side under the air cleaner. I've got some of the connections made, but can't find the others. If anyone has a diagram or a picture of that, it would be really helpful.

The routing for the A/C idle up is shown on the second page of the attached PDF. The vacuum source is manifold vacuum where the brake booster connects. The valve is mounted to the left side (drivers side) fender well.

Under the air cleaner, there is a VCV that clips under the passenger side of the air cleaner. It's a VCV that's used to purge the distributor cap. It's shown at the top of the first page in the PDF file.

Also on that side of the air cleaner is a temperature valve (HIC valve). It's shown on the drawing linked here: http://www.sweetillusions.org/toyota/fj60_vacuum_routing.gif

 

[pcperks]

2mbb, you are the man! That is exactly what I needed! That drawing is so much better then the other ones I have seen and what is in the manual. Thanks a million.

 

[Spike Strip]

So where are you now, in the re-smog ?

 

[pcperks]

I just took it for a nice little ride. Living right by TONS of trails, I took it out on a little shakedown run and it was good. Sounds like I have an intake leak though, so I'm going to have to check that out. I really hope I don't, since I don't want to have to break everything back down again. It's just too hot out here in the desert to be doing that all the time. Not to mention I don't have a garage. I might have one available for me to borrow here soon, but until then, this is where I do all my work on the 60

 

[Spike Strip]

Worth every penny:

- Harbor Freight Tools - Quality Tools at the Lowest Prices


As far as air leak: triple check all you vac hoses, including hose to the brake booster and even the booster itself can be a source of vac leak.

Looks good.

New CAT will certainly help when it comes time to smog.

 

[pcperks]

Nice canopy, but it gets windy as hell out here in the desert so that won't work. But thanks for the link.

I just got done doing the carb cleaner test for the intake and it looks like I may not have gotten the intake manifold tightened down good enough. So to check that I have to pull off a ton of crap.

But since it runs I'm gonna wait until I have a better place to work on it for now. I don't think a leak like this will cause me any major issues for right now. At least I don't think it will.

 

[Spike Strip]

You know, some people run a Remflex gasket with good results if they have a warped intake...

But if you have to take it off again, might find a machine shop to surface it. There's a guy down here in the SFV who does MAFs motors and rebuilds these intake/ex combos, if you can't find a local guy.

Do a search on here for Remflex -- NXLTACY and I put one on his truck and great so far, 6 months later.

 

[pcperks]

I wish I knew why it wasn't seating right. I do know putting it on, it didn't want to line up with the two studs coming off the head very well. I did a real basic check of it for warping with a straight edge and it didn't appear to be warped at all. I bought my manifold gasket from MAF and thought it was one of the high quality ones, but it apparently was OEM. There is a local machine shop here that is pretty good and I'll have to give them a call and see if they can machine it if it needs it.

It will probably be a couple weeks before I can get around to breaking it down again and seeing what the problem is. Guess I'll go ahead and look up the Remflex gasket and get one on order.

Thanks for the input Spike.

 

[pcperks]

I'm leaving in about 10 minutes to go to the smog station.

Going to drive around for about 30 minutes or so before hand to make sure everything is nice and hot before the test. Going to be the first person in this AM so no sitting and waiting around or anything.

I'm hoping all this work I've put into this cruiser so far is going to pay off today with being able to pass smog.

Cross your fingers and give a prayer to the Cruiser Gods that this goes well!

 

[pcperks]

OUCH!!!

So I didn't come close to passing smog. Apparently there are quite a few issues I have to take care of. After spending so much time doing all the vacuum hoses, being told they are all jacked up didn't make me feel any better.

Also I am missing the Thermostatic Air Cleaner. Have no idea what that even is, so that's always fun.

Not to mention when I get there, it's running like crap all of a sudden. Some of the stuff I can fix I hope, but below are the numbers so anyone that can chime in and let me know what I need to do in order to get this in compliance would be greatly appreciated. Some of it I understand I think, so it would be great if I can get some confirmation. Thanks a ton in advance.

I

 

[wngrog]

Gross Polluter....FAIL

:shaking:

California........

 

[pcperks]

Ok, after doing some research and looking up some more information, this where I think I need to go. One of you experts please let me know if this looks right or if I'm way off.

--Since my percentage of HC at idle is high, it is too rich and needs to be leaned out.

--CO is high at 2500rpm, with really low O2, so that tells me there is not any air being blown into the exhaust from the Air Injection to thin out the concentration of CO.

So to fix this, I'm pretty sure this is where I need to go with it:

1. Intake leak, have to fix to ensure good vacuum so all the air injection parts work right. At first I didn't think this was a really big deal but it apparently may be the main cause of most of my problems.

2. Check all the plugs and wires, since this morning it seemed like it was missing a little which could be a problem.

3. Verify all the vacuum lines again. Mechanic who did smog said my Air Injection lines weren't right, along with my VCV coming off the distributor, and off the EGR. I think he's full of it actually, but will go over them again to be safe, especially since it looks like I have an air injection issue. (Next time going to hand him the manual and all the drawings I can find before he starts.)

4. Perform the lean drop on the carb and make sure the mixture is all good and the idle and everything is set right.

Hopefully if I can get all of this done, it will be within standards. Thanks for any and all feedback on this.